Lexus ES: Installation

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / A25a-fxs (engine Mechanical) / Engine Unit / Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A:

(1) Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

(b) Type B:

(1) Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the 2 bolts.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the O-ring to the engine oil level dipstick guide.

(c) Using an 8 mm socket wrench, install the engine oil level dipstick guide to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the engine oil level dipstick.

3. INSTALL IGNITION COIL ASSEMBLY

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4. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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5. INSTALL FUEL DELIVERY PIPE

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6. INSTALL PORT FUEL INJECTOR ASSEMBLY

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7. INSTALL NO. 5 ENGINE WIRE

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8. INSTALL INJECTOR VIBRATION INSULATOR

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9. INSTALL NO. 1 DELIVERY PIPE SPACER

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10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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11. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

12. INSTALL NO. 6 ENGINE WIRE

(a) Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Engage the 2 clamps.

13. INSTALL SENSOR WIRE

(a) Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Engage the 3 clamps.

14. INSTALL NO. 7 WATER BY-PASS HOSE

(a) Install the No. 7 water by-pass hose and slide the 2 clips to secure it.

15. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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16. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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17. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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18. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) for EGR Valve Bracket Connection Type:

(1) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
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When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a	17 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

(2) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

(b) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a	17 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

(2) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

(3) Using an 8 mm socket wrench, install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

19. CONNECT FUEL TUBE SUB-ASSEMBLY

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20. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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21. INSTALL INTAKE MANIFOLD

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22. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (A).

(b) Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Using an 8 mm socket wrench, tighten the 2 bolts (B).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

23. INSTALL NO. 3 WATER BY-PASS PIPE

(a) Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.

(b) Using an 8 mm socket wrench, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

24. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) for EGR Valve Bracket Connection Type:

(1) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.

*a	Pin
*b	Hole

(2) Using an 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(3) Using an 8 mm socket wrench, connect the No. 1 fuel pipe sub-assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(1) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.

*a	Pin
*b	Hole

(2) Using an 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

25. INSTALL NO. 4 WATER BY-PASS HOSE

(a) Install the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

26. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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27. INSTALL EGR COOLER ASSEMBLY

(a) Install the EGR cooler assembly, a new EGR cooler gasket and EGR valve gasket with the 5 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(b) Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

28. INSTALL THROTTLE BODY GASKET

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29. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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30. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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31. INSTALL MANIFOLD STAY

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32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A:

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Type B:

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

33. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

(b) Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.

NOTICE:

Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet sub-assembly.
Make sure that the claws of the clip are within the location shown in the illustration.

*a	Paint Mark
*b	45° (Claw of Clip Location)

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

34. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Install the No. 2 water by-pass pipe sub-assembly with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(b) Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.

35. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

(a) Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Install the compressor with motor assembly with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolt and nuts in the order shown in the illustration.

36. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}

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